DW8 engine — removal and installation (Peugeot 206)

When removing and installing the engine at Peugeot service centers, use the following special tool:

• traverse - 0102-D
• flywheel stopper - 0188-F;
• hanging hooks;
• fork for removing the gearbox rods - 0102-G1 / -G2;
• mandrel for installing oil seals - 0317-T / -U.

Removing

Removing the power unit with the DW8 engine is carried out in the following order:

Note. The power unit is removed upwards.

- Establish a cover of a cowl in vertical position by means of adaptation;

• remove the decorative cover 5 (pic. 4.16);
• remove block 4 of the air cleaner with air ducts;
• remove the storage battery 3 from the pallet;
• remove block 2 preheating;
• unscrew two bolts 7;
• remove block 1 relay;
• remove the air filter housing;
• remove the battery tray support;
• disconnect and move aside the fitting 6 fuel supply pipes;
• remove the electronic control unit;

• disconnect wires 1 and 2 (pic. 4.17);

• disconnect tubes 1, 2, 3 (pic. 4.18);
• remove the front wheels;
• drain the oil from the gearbox;
• drain the coolant from the cooling system;
• remove the mudguards;
• remove the protective screen under the engine;
• remove the front wheel drives on both sides of the car;

• disconnect pin 1 (pic. 4.19) on the inner panel of the left front fender;

• release and move aside tube 1 (pic. 4.20) power steering, passing in the engine area;
• remove the protective board 2;
• Disconnect the exhaust pipe from the exhaust manifold side;

• install latch 1 (pic. 4.21);

• remove jet bracket 1 (pic. 4.22) engine mounts;

• without opening the refrigerant circuit of the air conditioning system, move compressor 1 aside (pic. 4.23);

Attention! Never kink the refrigerant circuit pipes of the air conditioning system.

• remove the front panel;
• move the power steering pump without opening the system circuit;
• disconnect and move aside the heat exchanger pipes at the level of the shield;
• disconnect and move aside the hose of the vacuum brake booster;

• move tank 1 (pic. 4.24) along with his pipes;
• move aside the flexible cable of the clutch drive or the clutch slave cylinder;
• disconnect the gearbox control rods using the tool;
• cover the tubes of the core of the condenser of the air conditioning system with a sheet of strong cardboard;
• remove the accessory drive belt;
• remove the generator;
• remove the crankshaft pulley;

• bring the lifting beam with hooks, hook on the lifting brackets 1 and 3 (pic. 4.25), and then tighten the cables;
• unscrew three bolts 2;
• unscrew nut 9;
• remove the right bracket 8 of the engine mount;
• unscrew nut 6;
• unscrew two bolts 7;
• remove the elastic pad 4;
• unscrew the two bolts 5 fastening the support;
• remove the caliper;
• disconnect and set aside the wiring harnesses, pipelines related to the gearbox or engine;

• remove the power unit upwards, keeping the sleeve 1 (pic. 4.26).

Installation

Install the power unit with the DW8 engine in the reverse order of removal, while observing the following:

• systematically replace self-locking nuts and seals at the outlet of the gearbox using mandrels;

Attention! Pack the space between the lips with grease before installing the seals.

• install the compressor following the installation sequence of the above parts;

Attention! Lock nut 1 (see fig. 4.14) fixes the rear upper part of the compressor.

• first tighten the crankshaft pulley bolts to 42 Nm, and then the oil filter bolts to 39 Nm;
• carefully observe the laying paths and attachment points of wire bundles and wiring harnesses;
• bring the oil level in the gearbox to normal;
• fill the engine cooling system and remove air from it;
• carry out programming of all electronic devices.